Device for counting courses in knitted fabric



I Sept. 15, 1959 c NEWTON ETAL 2,903,889

DEVICE FOR COUNTING COURSES IN KNITTED FABRIC Filed Oct. 22, 1954 3 Sheets-Sheet 1 1 lNVEiNTDRE BHARLE 5 [RN EWT [1N CHARLES ELGHUR EH Sept 15, 1959 c, NEWTON ETAL 2,903,889

DEVICE FOR COUNTING COURSES IN KNITTED FABRIC Filed. Oct. 22, 1954 3 Sheets-Sheet 2 INVBNTURB UHARLBE llNBWTUN CHARLES BLHURBH Sept. 15, 1959 c, NEWTON ETAL 2,903,889

DEVICE FOR COUNTING COURSES IN KNITTED FABRIC FiledOct. 22, 1954 3 Sheets-Sheet 3 lNVEINTURS CHARLES G NEWTUN BHARLBSE UHUREH United States Patent DEVICE FOR COUNTING COURSES IN KNITTED FABRIC Charles G. Newton, Hamilton, Ontario, and Charles E.

Church, Burlington, Ontario, Canada, assignors to Marvel Specialty Company, 'Paducah, Ky., a corporation of Kentucky Application October 22, 1954, Serial No. 464,148

16 Claims. (Cl. 73159) This invention relates to a method and device for automatically counting the number of courses or knitted loops per unit length in knitted fabric, and while it is applicable to the counting of courses in various types of knitted fabric it is particularly directed for use in the examination of ladies sheer hosiery; the object of the invention being to produce an invention capable of immediately indicating the number of courses per unit length.

Heretofore in an endeavour to obtain consistency in the knitting of stockings of predetermined lengths it has been the practice to stretch the fabric of the stocking either by hand or upon a frame to elongate the yarn loops so that they would be visible for counting under a strong light or a magnifying glass to the best of the checking persons visual perception. In the use of a frame, the stocking was stretched by being anchored at one end and pulled at the other end by a weight or spring, the theory being that the Weight or spring would give successive pieces of fabric the same unit length stretch. While this theory had a possible validity in comparing exactly similar fabrics, it was of little commercial practical value as the application of the fabric stretching force might in one instance be insufficient to completely stretch the yarn loops and yet at the same time stretch them sufiiciently to be accepted to be fully stretched as visible to the eye, but in another instance if the yarn loops were subjected to a pull beyond their full stretch, the yarn particularly in the case of nylon which is elastic, would commence to stretch and result in over-stretched loops.

It will thus be apparent that without some method of determining when the loops were fully stretched, and no more, that it was impossible to arrive at any norm of courses per unit length upon which to establish a true standard.

It will also be apparent that visual course counting is entirely dependent upon the concentration and accuracy of the person so employed. For example, a 66 gauge nylon stocking has approximately 38 to 40 courses per inch when stretched to yarn loop collapsing tension. Con sidering an inch unit of length which is the maximum usually employed on account of the time required to visually count, in combination with half or one third loop lengths that may have to be guessed at the end of the inch count, together with the inaccuracies in determining when enough weight or spring tension had been applied to stretch the fabric loops to an established norm, it was impossible to secure a count that is very much closer to accuracy than guess work.

The purpose of this invention is to devise a method of counting the courses of knitted fabric by stretching or collapsing the loops to and not beyond a norm wherein the rounded end portions of side-by-side intertwined loops are drawn into a series of parallel transverse loop or course defining ridges formed on one side of the fabric;

the ridges having sufiicient protuberance to be rapidly counted by passing an electric pulse totalizing counter of the device thereover. A particular object of the invention is to design the 2,903,889 Patented Sept. 15, 1 959 device wherein the method for preparing the fabric for course counting may be accurately controlled, and to this end the device is so designed that when the fabric has been stretched upon the device to the point where the loops have collapsed to the established norm, a lock is instantly applied to stop further stretching of the fabric. In the illustrated embodiment of the device the lock motion against further fabric stretch is coupled to the control switch of the electric pulse totalizing counter whereby the counter commences its actuation in synchronization with the stretch locking motion.

A further object of the invention is to so design its mechanism that it will repeatedly recount as long as the locked tension is maintained upon the fabric; though any slight release of the fabric tension will cut off the current to the electric pulse counter, and thus indicate that the correct norm tension was not being maintained.

Another and useful object of the invention is to so design the course count indicating mechanism that its pointer always returns to the zero mark on its dial before the commencement of a count or recount.

Other objects and advantages will be apparent from the following detailed description taken in conjunction with the attached drawings, in which:

Figure 1 is a front elevational view of the device.

Figure 2 is a plan view of the device.

Figure 3 is a vertical cross-sectional view through the device, taken through the line 3--3, Figure 1.

Figure 4 is a vertical cross-sectional view through the device, taken through the line 44, Figure 2.

Figure 5 is a plan view of the reset mechanism for returning the count indicating pointer to the zero mark on the dial before the commencement of a count or recount, being taken through the line 55, Figure 3, and showing the sector thereof in the vicinity of the bottom of its swing.

Figure 6 is an enlarged plan view of a fragmentary portion of the slotted plate within which slot the course counter slides, the counter being included in the view.

Figure 7 is a vertical cross-sectional view through the counter and its housing, being taken through the line 7--7, Figure 6.

Figure 8 is an enlarged cross-sectional view of the electro-magnetic mechanism for totalizing the course pulsations of the course counter, being taken through the line 88, Figure 3.

Figure 9 is a highly magnified view of a non-stretched piece of knitted fabric, such as a nylon stocking.

Figure 10 is a similar view to Figure 9, and showing the loops of the knitting collapsed but not distorted under fabric stretch tension.

Figure 11 is a highly magnified view of the fabric course pulsated plunger of the course counter, the stretched fabric being shown in a position thereon wherein the plunger is not depressed; a fabric course being positioned on either side of the top of the plunger, and

Figure 12 is a similar view to Figure 11, the plunger being shown depressed under the action of a fabric course passing thereover.

The device is broadly made up of three interconnected elements, wherein the first element consists of the arrangement for tensioning the fabric being examined to its predetermined loop collapsing stretch and at which moment the element is locked against further stretching action; the second element consisting of a course counter having a plunger capable of being pulsated by the passage of the plunger head over the loop or course defining ridges formed in the stretched fabric, the actuation of the course counter being controlled by the first element fabric tension; and the third element comprising an electromagnetic count totalizing mechanism actuated by the second course counting element and indicating to the operator the number of courses in a unit length of the fabric under examination.

Referring, to Figures 1 to 4 which show the fabric stretching element, the device has a boxlike housing 2 carrying a pair of spaced apart stationary spindles 3 and 4 protruding from the upper portion of the front face 5 of the housing 2. A sleeve 6 is freely mounted upon the spindle 3, and a sleeve 7 freely mounted upon the spindle 4; the sleeve 6 carrying a roller 8, and the sleeve 7 a roller 9. The fabric 18 to be examined is placed across the top of the rollers, as shown in dotted lines in Figure l.

A downwardly extending arm 11 is secured to the sleeve 6 to swing in unison with movement of the sleeve and its roller 8. A micro-plunger switch 12. is mounted upon the face 5' of the housing to be actuated by the swinging movement of the arm 11, as illustrated in Figure 4. To retain the fabric against sliding upon the roller 8, a swingable arm 13 is mounted upon the face 5 of the housing below the roller and carries a roller 14 upon its free end and arranged to bear against the fabric on the roller 8 when the arm is in the in-swung position, as shown in dotted lines in Figure l. A tension spring 15 extends from a pin 16 on the face 5 to the central portion of the arm 13', the arrangement being such that the spring is under continuous tension whereby the roller 14 is either pressed against the roller 8 in the inswung position or the arm 13 pressed against the stop stud 17 in the out-swung position.

The sleeve 7 upon the spindle 4 carries a fine toothed ratchet wheel 18 which is retained against movement in a counter-clockwise direction by a spring held pawl 19 mounted upon the housing face 5. A second spring held pawl 28 is also mounted upon the face 5 to be engagable with the ratchet wheel, its spring tending to hold thepawl out of engagement with the ratchet wheel. The arm 11 carries a branch arm 21 designed to swing therewith and press the pawl into engagement with the ratchet wheel 18, a pawl engaging adjusting screw 22 being carried upon the outer end of the branch arm.

The movement of the arm 11 in a clockwise direction (Figure 4) to close the switch 12, is in opposition to the tension of a spiral spring 23 secured at one end to the end of the arm, and at the other end to a bell-crank lever 24 pivotally mounted upon the housing face 5. Manual adjustment of the lever across the stations 25 alters the pressure to be exerted to swing the arm 11. to close the switch 12.

In operating the fabric stretching element, as has now been described, the fabric 10 is laid across the rollers 8 and 9, and the arm and roller 13 and 14 manually swung into the fabric engaging position shown in dotted lines in Figure 1. The rollers 8, 9 and 14 are made of a rubher-like material to which the fabric will cling with little tendency to slip. The roller 9 and the fabric extending thereover is then turned in a clockwise direction between the thumb and forefinger of the operator, moving the hanging portion A of the fabric to substantially the position E, Figure 1. As the left hand end of the fabric is anchored between the roller 14 and the roller 8, rotation of the roller 9 stretches the fabric, the roller being retained against counter-clockwise movement by the pawl 19 engaging the ratchet wheel 18 whereby the tension put upon the fabric is mechanically retained.

The stretching of the fabric between the rollers 8 and 9 is allowed to continue until the fabric has been stretched to a point wherein the loops are taut and collapsed to a norm wherein the rounded end portions 18a of side-byside interlocked loops are drawn into a series of parallel loop or course defining ridges 10b on the under side of the fabric, as shown in the magnified views, Figures 10 to 12. The tensions in the plunger of the switch 12 and the spring 23 are so adjusted that at the instant the fabric stretch norm has been reached, the fabric tension urge to move the roller 8 in a clockwise direction will be suffi cient 4 to rotate the roller and its sleeve 6 several degrees whereby the swinging movement of the arm 11 will close the switch 12, and at the same instant the downward movement of its branch arm 21 will swing the pawl 20 into engagement with the ratchet wheel 18; the ratchet wheel being thus locked against clockwise movement by the pawl 20 and counter-clockwise movement by the pawl 19. It will be appreciated that the instant the pawl 20 is applied the fabric will be under its predetermined norm stretch and the roller 9 and fabric held thereon locked against movement. The closing of the switch 12 closes the electrical circuit 70 to the motor of the course counting element which shall now be described.

A horizontal plate 26 is mounted upon the face 5 of the housing between the rollers 8 and 9 and beneath the horizontal plane between the tops of the rollers. A slot 27 extends lengthwise through the plate centrally of the width of the rollers, as shown in Figure 2. The course counter mechanism is carried by a casing 28 slidable to-and-fro across the under face of the plate 26, and formed with a top rib 29 slidable within the slot 27. A nipple 30 is carried upon the casing rib 29 to project upwardly through the slot 27, the threaded lower portion 31 of the nipple being of less diameter than the width of the slot to be slidable therein and carrying a slipper plate 32 positioned between the shoulder of the head of the nipple and the top face of the plate 26.

The counter casing 28 contains a pivotally mounted electrical contact make-and-break arm 33 which is urged upwardly by a spring 133 into contact with a contact point 34 threaded into the top of the casing through its rib 29 so that it is accessible for adjustment rotation, as shown in Figure 6. A fabric course pulsated plunger 35 freely extends through the nipple 30 and rests upon the arm 33 whereby pulsations :of the plunger will make and break the electrical circuit 63 through actuation of the arm 33. The top face of the nipple is formed with a shallow central depression 36, and a fabric ridge receiving crossg roove 37 opening thereinto, the plunger orifice 38 being positioned centrally of the depression. Upon reference to Figure 2 it will be seen that the rollers 8 and 9 are each of considerably greater width than the diameter of the nipple 30 and that therefore the band of fabric stretched between the rollers will also be of considerably greater width than the diameter of the nipple. As the top of the nipple is higher than the horizontal plane across the tops of the rollers, as shown in Figure 1, the band of fabric tensioned between the rollers slopes downwardly from every part of the periphery of the top of the nipple and whereby the courses 10b in the stretched band of fabric are successively drawn downwardly into the cross groove 37 to depress the plunger 35 as the nipple travels along the bottom of the tensioned fabric band as illustrated in the highly magnified views of Figures 11 and 12.

To move the counter assembly to-and-fro across the plate 26, an electric motor and reduction gear assembly 38' is mounted within the housing 2 with its driving shaft 39 projecting. through an orifice in the housing front face 5. A crank wheel 40 having a crank pin 41 is mounted upon the shaft 39. A crank oscillated lever 42 is swingably mounted upon a boss 43 positioned beneath the shaft 39, the lever having a slot 44 within which the crank pin 41 rides as the rotation of the pin oscillates the lever. The upper end of the lever is formed with a crutch 45 straddling a pin 46 projecting from the rear face of the counter housing 28. The energization of the motor assembly 38 is controlled by the switch 12, the closing of the switch by the clockwise swinging motion of the lever 11 starting the motor with the resultant reciprocating motion of the counter assembly.

The third or elcctro-magnetic count totalizing mechanism is contained within a casing 47 having a graduated dial 48 positioned upon the top face of the housing 2, the casing being contained within the housing underneath the top face. A spindle 49 extends through the casing, carrying a count indicating dial pointer 50 upon its upper end and a ratchet wheel 51 intermediately of its length within the casing 47. An arm 52 is oscillatably mounted upon the spindle 49 alongside the ratchet wheel and carries a pivotally mounted pawl 53 engageable with the ratchet wheel teeth to rotate the wheel, as shown by the arrow in Figure 8. The arm 52 is swung in an opposite direction to the arrow by an electro-magnet 54 energized by the circuit 63 through the course counter, and in the same direction as the arrow by a tension spring 55; the spring extending from a plate 67 in the casing to the pawl and so positioned that it always tends to draw the pawl into the teeth of the ratchet wheel when swinging the arm 52. An adjustable stop screw 56 to limit the spring urged movement of the arm 52 is mounted upon the plate 67 and arranged to engage the pawl in the vicinity of its free end, whereby the pawls engagement with the end of the stop screw retains the pawl in tight engagement with the ratchet wheel teeth to stop any tendency of the rapidly rotating ratchet wheel to overrun the arm and pawl impulse under the tension of the spring 55. A second ratchet wheel engaging spring urged pawl 57 is pivotally mounted upon 'a plate 58 within the casing, and is provided for the purpose of retaining the wheel against any tendency to rotate in the opposite direction to the arnow under the magnetically urged movement of the arm and its nawl.

.The' count indicating dial point 50 is automatically returned to the zero point, as shown in Figure 2, before the commencement of each fabric course count. The pointer return mechanism is shown in Figures 3 to 5, and comprises a sector shaped plate 59 mounted upon the end of the driving shaft 39 contained within the housing 2. A segmented disc 60 having a flat edge portion 61 is carried upon the lower end of the dial pointer spindle 49 which protrudes from the bottom of the easing 47 and is so arranged that its circular edge 62 is frictionally contacted by the face of the sector plate 59 in its rotation. The sector plate is so dimensioned in relation to the length of the circular edge 62 of the disc 60 that if necessary the rotation of the plate will frictionally contact and rotate the disc along the entire length of its circular edge 62. The rotation of the disc by the sector plate ceases when the disc rotates into a position wherein the juxtaposition of its flat edge 61 breaks the frictional drive. At this point, as illustrated in Figure 5, the dial pointer 50 has been rotated by the disc to zero in coincidence with the point at which the friction rotation of the disc by the sector plate ceases.

The sector plate 59 is so positioned upon the driving shaft 39 in relation to the crank angularity of the crank pin 41 and the resultant oscillation of the lever 42 that during the count the sector plate swings downwardly away from the rotating disc 60 to only swing upwardly and approach the disc upon completion of sufficient turning movement of the driving shaft 39 to slide the course counting casing 28 through the length of its course counting stroke, the further rotation of the driving shaft during'the return stroke of the counter casing swinging the sector plate into contact with the disc.

To limit the transmission of electrical impulses from the course counting mechanism to the count totalizing mechanism to movement of the nipple 30 in onedirection, as from left to right asshown in Figure l; a distributor switch is incorporated in the circuit 63 of the course counting element and which is grounded through the device. As illustrated in Figures 3 and 4 the distributor comprises a disc 64 of insulating material mounted upon the driving shaft 39 whereby it rotates in unison with the crank wheel 40. A contact plate 65 grounded to the device through a lead 67 is carried upon the face of the disc for engagement by a brush 66. The contact plate is so dimensioned and arranged that contact with the brush is only made when the nipple 30 is moving from left to right in its travel. During the return movement of the nipple from right to left the course counting plunger 35 is pulsated by the courses if the fabric has not been removed, but as the electrical connection has been broken through the distributor plate 65 being out of contact with the brush 66 the count totalizing mechanism is not actuated.

It is believed that the operation of the device will be readily understood from the foregoing description. At the commencement of the counting travel of the nipple from left to right the sector plate 59 is substantially in the position shown in dotted lines in Figure 4 and out of frictional contact with the disc 60, the flat face 61 of the disc being in the position shown in dotted lines in Figure 5 and the dial pointer 50 at zero. During the counting the pointer and disc rotate, as does the sector plate 59. When the course count of the fabric is finished sthe crank lever 42 and the nipple 30 are in the vicinity of the extremity of their left to right movement, and the distributor plate 65 out of contact with the brush 66, the dial pointer being at rest and indicating the count on the dial. As the crank mechanism moves from right to left the sector plate swings into frictional contact with the disc 60 to rotate it into the position shown in dotted lines in Figure 5 and whereby the dial pointer is returned to zero at the point where contact between the sector plate and the disc 60 is broken.

To accommodate a seam in hosiery where a count is required close to the scam, the roller 8 is formed with a trough 68 to receive the seam, the fabric adjacent to either side of the seam being placed in the path of travel of the nipple plunger 35.

What we claim as our invention is:

l. A mechanism for determining the number of courses in a unit length of extended knitted fabric, and comprising means for stretching the fabric having an element movable from an initial position to a displaced position in response to a predetermined tension wherein the intertwined end portions of side-by-side fabric yarn course loops are extended into a series of parallel course defining ridges, and a ridge impulsed course counting mechanism arranged for pulsation by the course defining ridges in the extended fabric through movement across the ridges and in contact therewith, and means for so moving the counting mechanism actuated by said one element of said fabric stretching means in its displaced position, whereby the counting is accomplished only while said one element is in its displaced position.

2. A mechanism for determining the number of courses in a unit length of extended knitted fabric, and comprising means for stretching the fabric to a predetermined tension wherein the intertwined end portions of side-by-side fabric yarn course loops are extended into a series of parallel course defining ridges, means for counting the number of course defining ridges in the unit length extended fabric by relative contacting move ment of the means and the ridges, means for subjecting said counting means and said length of extended fabric to relative movement across the ridges, and means responsive to the fabric tensioned condition of said means for stretching operatively connected to said moving means for actuating the same, whereby the counting is accomplished only while the said fabric tensioned condition of said means for stretching is maintained.

3. A mechanism for determining the number of courses in a unit length of extended knitted fabric, and comprising a pair of spaced apart fabric engaging members between which the fabric is extended to a tension wherein the intertwined end portions of side by-side fabric yarn course loops are extended into a series of parallel course defining ridges, one of said fabric engaging members and the portion of the fabric engaged thereby being moveable in relation to the other member and the fabric engaged thereby to exert the tension on the fabric, said other member being movable in response to said tension,

7 a ridge impulsed course counting mechanism arranged for pulsation by the course defining ridges in the ex tended fabric through movement across the ridges and in contact therewith, and means for so moving the counting mechanism actuated by movement of said other member.

4. A mechanism as defined in claim 3 comprising means for locking the one movable fabric engaging member against further tensioning of the fabric when a pre determined fabric extension has been attained.

5- A mechanism as defined in claim 3 comprising means for locking the said one movable fabric engaging member against further movement by the fabric tension when a predetermined fabric extension has been attained.

6. A mechanism as defined in claim 3 wherein means is provided for locking the said one moveable fabric engaging member against further movement when a predetermined fabric extension has been attained, said means being actuated by the tension in the fabric.

7. A mechanism as defined in claim 3 which includes means for locking the fabric tensioning member against further movement when a predetermined fabric tension has been attained, said means being actuated by the movement of the other member.

8. A mechanism as defined in claim 3 wherein the moveable fabric tensioning member is rotatable and comprising means for locking said movable fabric tensioning member against further rotation by the fabric tension when a predetermined fabric extension has been attained.

9. A mechanism as defined in claim 3, wherein the said one member isrotatable, and which includes a brake element for engagement with the rotatable member when a predetermined fabric tension has been attained, and means actuated by movement of the other member for applying the brake.

10. A mechanism as defined in claim 3, which includes an element for locking the fabric tensioning member against further movement when a predetermined fabric tension has been attained, an electric motor for moving the course counting mechanism, and a switch controlling actuation of the motor and operating in unison with the fabric tension locking element.

11. A mechanism as defined in claim 3, wherein the means for moving the counting mechanism comprises an electric motor, and the course counting mechanism comprises an electro-magnet, an electric circuit to the magnet, a fabric ridge pulsated switch in the circuit, a member rotated by the electro-magnet in synchronization with the pulsated switch, a course count totalizing element actuated by the rotated member, a graduated dial and total count indicating pointer incorporated in the totalizing element, the pointer being actuated by the electro-magnet rotated member, and means rotatable in unison with the electric motor for returning the pointer from the total count indication graduation to the zero count graduation on the dial upon completion of the totalizing count by the totalizing element.

12. A. mechanism as defined in claim 3, wherein the means for moving said counting mechanism comprises an electric motor, and the course counting mechanism comprises an electro-magnet, an electric circuit to the magnet, a fabric ridge pulsated switch in the circuit, a member rotated by the electro-magnet in synchronization with the pulsated switch, a course count totalizing element actuated by the rotated member, a graduated dial and total count indicating pointer incorporated in the totalizing element, a rotatable spindle carrying the pointer and rotating in unison with the electromagnet rotating member, a shaft rotated by the electric motor; a mech: anism for returning the pointer to the zero graduation on the dial upon completion of the totalizing count and comprising a flat faced radial plate secured at one of its ends to the shaft to rotate therewith with its flat face traversing a path at right angles to the axis of the shaft, a disc having a flat in its circular edge and connected to the pointer spindle to rotate therewith and positioned. to have its circular edge frictionally driven by the flat face of the motor rotated radial plate during a portion of its rotation, the flat in the disc edge being arranged to be in juxtaposition with the flat face. of the radial plate when the pointer is at the zero graduation.

13. A mechanism as defined in claim 2, wherein said fabric stretching means comprises two spaced apart fabric supporting members which are movable, one member being moveable to tension the fabric and the other member moveable under tension of the fabric, an element for locking the fabric tensioning member against further movement when a predetermined fabric tension has been attained, said means for moving the course counting mechanism comprising an electric motor, and said tension responsive means including a switch controlling actuation of the motor and arranged to be. retained in the closed position by the ridge defining fabric tension and to open upon release of the ridge defining fabric tension.

14. A mechanism for determining the number of courses in a unit length of extended knitted fabric; and comprising means for. stretching the fabric to a predetermined tension wherein the intertwined end portions of side-by-side fabric yarn course loops are extended into a series of parallel course defining ridges, an electrically actuated ridge impulsed course counting mechanism arranged for pulsation by the course defining ridges in the extended fabric through movement across the ridges and in contact therewith, and an electric switch controlling the course counting mechanism and actuated by said fabric stretching means.

15. A mechanism as defined in claim 14, comprising means for locking the fabric against further tensioning when the predetermined fabric extension has been attained.

16. A mechanism for determining the number of courses in a unit length of extended knitted fabric, comprising means for stretching the fabric to a predetermined tension whereat the intertwined end portions of side-byside fabric yarn course loops are extended into a series of parallel course defining ridges, a source of power, and a ridge impulsed course counting mechanism arranged for pulsation by the course defining ridges in the extended fabric and actuated for movement transversely of the ridges by the source of power, and said means for stretching the fabric actuating the said source of power.

References Cited in the file of this patent UNITED STATES PATENTS 1,817,617 Goseh Aug. 4, 1931 2,117,402 Cobert May 17, 1938 2,326,768 Eddy Aug. 17, 1943 2,511,202 Fulboam June 13, 1950 2,580,192 Potter Dec. 25, 1951 2,589,741 Slechta Mar. 18, 1952 FOREIGN PATENTS 542,887 Great Britain Jan. 30, 1942 

